CN218631427U - High temperature resistant anti-interference flexible cable - Google Patents
High temperature resistant anti-interference flexible cable Download PDFInfo
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- CN218631427U CN218631427U CN202222257434.2U CN202222257434U CN218631427U CN 218631427 U CN218631427 U CN 218631427U CN 202222257434 U CN202222257434 U CN 202222257434U CN 218631427 U CN218631427 U CN 218631427U
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Abstract
A high-temperature-resistant anti-interference flexible cable is composed of a cable core formed by twisting cable cores and a protective layer outside the cable core. The cable core comprises a ground wire core and a plurality of power wire cores which are twisted to form a cable core, and a flexible temperature-resistant twisted fiber is filled in the axial position of the cable core; the protective layer comprises a composite shielding layer and an outer protective layer which are wrapped outside the cable core from inside to outside; the gaps among the wire cores in the composite shielding layer are filled with an inner liner layer made of flexible temperature-resistant materials; the composite shielding layer comprises an inner aluminum foil metal shielding layer, a tinned copper wire mesh grid and an outer aluminum foil metal shielding layer from inside to outside; the inner aluminum foil metal shielding layer and the outer aluminum foil metal shielding layer are formed by overlapping and wrapping aluminum foil mylar tapes; the tinned copper wire mesh grid is formed by weaving tinned copper wires, the diameter of each tinned copper wire is not more than 0.2mm, and the weaving density is 88-90%. The cable has the main performance characteristics of excellent electromagnetic compatibility requirement and solves the problems of aging, durability and flexibility of the cable.
Description
Technical Field
The utility model belongs to the technical field of the cable, specifically a high temperature resistant anti-interference flexible cable.
Background
In the prior art, a cable for an automobile is known as a blood vessel and a nerve of a new energy automobile, in the continuous evolution process of the new energy automobile, the new energy automobile is not only used as a vehicle, various functions of the automobile are continuously innovated, each key part is bound to face more and more network interference without losing the function, when the electric automobile runs, the repeatedly changed electrical load and the frequency conversion technology which is adopted in a large amount in the system cause severe fluctuation of voltage and current of the cable, and generate larger EMC electromagnetic interference, influence is caused on the electric automobile and electronic and electrical product equipment of the surrounding environment, and therefore the shielding design for protecting the electromagnetic interference is considered when the cable and the wiring harness are designed and selected, so that the requirement of the whole automobile on the electromagnetic compatibility is met.
Secondly, the current transmission of a high-voltage wire harness in the new energy automobile is frequent, the heating and ageing durability of the cable are tested, the bending construction requirements of the vehicle-mounted plug-in are limited, and new requirements on the durability, reliability, heat resistance and softness of the cable are provided.
Disclosure of Invention
The present cable provides a solution to the above systematic problems.
The utility model discloses a high temperature resistant anti-interference flexible cable constitutes the cable core by the sinle silk transposition, and the cable core protects the inoxidizing coating outward and constitutes. The cable core comprises a ground wire core and a plurality of power wire cores which are twisted to form a cable core, and a flexible temperature-resistant twisted fiber is filled in the axial position of the cable core;
the protective layer comprises a composite shielding layer and an outer protective layer which are wrapped outside the cable core from inside to outside; the gaps among the wire cores in the composite shielding layer are filled with an inner lining layer made of flexible temperature-resistant materials;
the composite shielding layer comprises an inner aluminum foil metal shielding layer, a tinned copper wire mesh grid and an outer aluminum foil metal shielding layer from inside to outside;
the inner aluminum foil metal shielding layer and the outer aluminum foil metal shielding layer are formed by overlapping and wrapping aluminum foil mylar tapes;
the tinned copper wire weaving mesh is formed by weaving tinned copper wires, the diameter of each tinned copper wire is not more than 0.2mm, and the weaving density is 88-90%.
The annealed soft copper conductor is thinner by adopting 6 types of monofilaments, and the diameter range of the monofilaments is 0.1-0.20 mm; the elongation of the conductor monofilament is 23-30%. The conductor is made of oxygen-free copper,oxygen content is not more than 0.001%, volume resistivity at 20 deg.C is not more than 0.01701 omega.mm 2 /m。
The power wire core insulation layer and the ground wire core insulation layer are made of a thermosetting insulation material capable of resisting 150 ℃, and the specific type of the insulation material is a 150 ℃ irradiation polyolefin insulation material. The insulating material is a halogen-free environment-friendly material with high insulation resistance, aging resistance and softness, and the measured value of the insulation resistivity at 20 ℃ is 10 15 Omega cm, far superior to the 109 omega mm requirement in the national/international standard.
The flexible temperature-resistant twisted fiber filling adopts twisted composite filling ropes, and the requirements of resisting 175 ℃ and 7d aging test are met, and the fiber is not embrittled.
The lining layer is made of a thermosetting flexible temperature-resistant material, and has excellent high and low temperature resistance, weather resistance, flame retardance and environmental protection.
The composite shielding layer is composed of an inner aluminum foil metal shielding layer, a tinned copper wire mesh grid and an outer aluminum foil metal shielding layer. The aluminum foil mylar tape is wound to form an inner aluminum foil metal shielding layer and an outer aluminum foil metal shielding layer, and the thickness requirement of the aluminum foil mylar tape is 0.05mm.
The tinned copper wire mesh grid adopts a tinned copper wire with high conductivity and corrosion resistance, the diameter of the weaving wire is not more than 0.2mm, the weaving pitch (28-32) mm and the weaving density is 88-90%.
And the lapping and covering rate of the aluminum foil mylar tape of the outer aluminum foil metal shielding layer is not less than 25% of the bandwidth.
The sheath layer is tightly extruded on the surface of the aluminum foil Mylar belt; the sheath layer is composed of a thermosetting sheath capable of resisting temperature of 150 ℃, and the specific type is 150 ℃ irradiation polyolefin sheath material. The sheath material is a halogen-free environment-friendly material with high tearing resistance, wear resistance, aging resistance and softness.
The aluminum foil mylar tape is formed by compounding and bonding non-hygroscopic polyester and pure aluminum foil together;
the thickness requirement of the aluminum foil mylar tape winding tape of the inner aluminum foil metal shielding layer is 0.05mm; aluminum foil mylar tape wrapping belts are uniformly overlapped and wrapped on the surface of the lining layer through a double-end wrapping machine, the aluminum surface faces outwards, and the width of the wrapping cover-lapping rate is not less than 5mm. The aluminum foil Mylar tape meets the determination requirement of RoHS2.0 in RoHS instruction 2015/863/EU.
The weaving density of the tinned copper wire weaving net is 88-90 percent, and the weaving angle range is 35-40 degrees.
The requirement of the aluminum foil mylar tape of the outer aluminum foil metal shielding layer comprises the following steps: the aluminum surface faces inwards, and the thickness is required to be 0.05mm. The tin-plated copper wire braided net is uniformly lapped and wrapped on the surface of the tin-plated copper wire braided net through a double-head lapping machine, and the lapping and covering rate is not less than 25% of the bandwidth.
The design of the composite shielding layer can achieve the shielding impedance less than 30m omega/m and the shielding attenuation more than or equal to 61dB.
The power wire core and the ground wire core conductor adopt a twice compound stranding conductor mode, a plurality of soft copper wires are stranded to form a twice stranding conductor, a plurality of annealing copper wires are stranded to form a bundle, each bundle of annealing copper wires is stranded to form a folded wire, the ratio of the stranding pitch diameter of the outermost layer of the compound stranding is not more than 14 times, and the direction of the inner layer and the outer layer is the left direction; the design can be used as one of important factors for effectively improving the bending flexibility of the cable.
The cable is made of cable materials and is specially designed for the cable structure, so that the cable can be adapted to the connection of a high-voltage wiring harness power supply in a new energy automobile. Compared with the similar cable, the cable has the main performance characteristics of excellent electromagnetic compatibility requirement and solves the problems of aging, durability and flexibility of the cable.
Drawings
Figure 1 is a schematic radial cross-section of the cable of this embodiment,
in the figure: conductor 1, insulating layer 2, sinle silk 3, flexible temperature resistant twisting type fibre fill 4, inner liner 5, interior aluminium foil metallic shield 6, tinned copper wire mesh grid 7, outer aluminium foil metallic shield 8, restrictive coating 9.
Detailed Description
The present invention will be further described with reference to the following specific embodiments:
referring to fig. 1, a high temperature resistant anti-interference flexible cable has a structure that a conductor 1 is formed by multiple strands of copper strands which are formed by combining annealed soft round copper wires; the conductor 1 is wrapped with an insulating layer 2 to form a single wire core 3, and a plurality of wire cores 3 (ground wire cores and power wire cores respectively) and a flexible temperature-resistant twisted fiber filling rope 4 are twisted to form a cable core; tightly extruding and wrapping the surface of the cable core to form an inner liner layer 5, overlapping and wrapping an aluminum foil wheat pulling belt outside the inner liner layer 5 to form an inner aluminum foil metal shielding layer 6, wrapping a tinned copper wire mesh 7 outside the inner aluminum foil metal shielding layer 6, overlapping and wrapping an aluminum foil wheat pulling belt outside the tinned copper wire mesh 7 to form an outer aluminum foil metal shielding layer 8, and wrapping a sheath layer 9 outside the outer aluminum foil metal shielding layer 8;
the tinned copper wire mesh grid is formed by weaving tinned copper wires, the diameter of each tinned copper wire is not more than 0.2mm, and the weaving density is 88-90%.
The thickness of the aluminum foil wheat pulling belt of the inner aluminum foil metal shielding layer and the thickness of the aluminum foil wheat pulling belt of the outer aluminum foil metal shielding layer are both 0.05mm.
The aluminum surface of the aluminum foil mylar tape of the inner aluminum foil metal shielding layer is back to the cable core, and the width of the lapping cover is not less than 5mm; the aluminum surface of the aluminum foil mylar tape of the outer aluminum foil metal shielding layer faces the cable core, and the lapping and covering rate is not less than 25% of the bandwidth; the performance requirement of the aluminum foil wheat pulling strip is that the requirement of RoHS2.0 determination in RoHS instruction 2015/863/EU is met.
The weaving angle range of the tinned copper wire woven mesh is 35-40 degrees.
The conductor is an annealed soft copper conductor composed of 6 types of monofilaments; the diameter range of the monofilament is 0.1-0.20 mm; the elongation of conductor monofilament is 23-30%; the conductor is made of oxygen-free copper, and has oxygen content not greater than 0.001%, and volume resistivity not greater than 0.01701 omega.mm at 20 deg.C 2 (ii)/m; the insulating layers are all made of thermosetting insulating materials which can resist the temperature of 150 ℃.
The conductors of the power wire core and the ground wire core are of twice-compound-stranded conductor structures: a plurality of monofilaments are twisted into one bundle, and each bundle of monofilaments are combined and bunched to form a folded yarn; the outermost layer of the compound twist has a twist pitch diameter ratio not more than 14 times, and the direction of the inner layer and the outer layer is the left direction.
The flexible temperature-resistant twisted fiber filling is a twisted composite filling rope, and the temperature resistance is required to be resistant to 175 ℃ for 7d and not embrittled in an aging test.
The sheath layer is made of a thermosetting sheath material which can resist the temperature of 150 ℃.
1) The conductor in the conductor is an annealed soft copper conductor, the annealed soft copper conductor is made of 6 types of monofilaments which are thinner, and the diameter range of the monofilaments is (0.1-0.20) mm; the elongation of conductor monofilament is 23-30%. The conductor is made of oxygen-free copper with low oxygen contentAt 0.001%, and at 20 deg.C, the volume resistivity is not more than 0.01701 omega.mm 2 And/m. A plurality of metal monofilaments are twisted into a bundle, and the plurality of metal monofilaments are divided into a plurality of layers from inside to outside; two adjacent strands of metal monofilaments in each layer of metal monofilaments are tightly attached to each other; in the two adjacent layers of metal monofilaments, the inner layer metal monofilament and the outer layer metal monofilament are tightly attached; the monofilament is an annealed soft round copper wire.
2) The insulating layer is formed by irradiating and crosslinking a PE insulating material at 150 ℃; the thickness of the insulating layer is (0.40-1.20) mm; the main base material of the insulating material polyolefin insulating material is halogen-free PE material, and the general base material is high-density polyethylene compounded with low-density polyethylene; in this example, the grade of the insulating material is PES-X2.
3) The flexible temperature-resistant twisted fiber filling rope is a twisted composite filling rope, and meets the requirements of flexibility of cables, temperature resistance of 175 ℃ x 7d and no embrittlement in an aging test.
4) The flexible temperature-resistant material of the inner liner is made of silicon rubber; the thickness of the lining layer is (0.3-0.8) mm, the color of the lining layer is gray, and in the example, the grade of the lining layer material is TWN-E/SIR.
5) The aluminum surface of the inner aluminum foil metal shielding layer faces outwards, and the lapping and covering rate is not less than 5mm. The lapping and covering rate of the outer aluminum foil metal shielding layer is not less than 25%;
the diameter of the weaving wire in the tinned copper wire weaving net is (0.1-0.2) mm, the weaving wire density is 88-90%, the weaving angle range is 35-40 degrees, and the weaving pitch is (28-32) mm.
6) The sheath layer is formed by irradiating and crosslinking a 150 ℃ PE insulating material; the thickness of the sheath layer is 1.2-1.80 mm; in this example, the material, type/brand of the sheathing material is the same as the insulating layer.
During the manufacturing process:
1) The wire core is obtained by electron accelerated irradiation, the irradiation energy (1.2-1.3) MeV, the dose (350-400) kGy and the beam current less than or equal to 40mA parameters are set in sequence for 18-20 times, and the power wire core and the ground wire core are subjected to irradiation crosslinking and grounding discharge.
2) The sheath layer is irradiated for 6-8 times, irradiation energy (2.2-2.4) MeV, dosage (100-140) kGy and beam current are less than or equal to 28mA, irradiation crosslinking is completed, and the finished cable is grounded and discharged for at least 12 hours.
3) The aluminum foil mylar tape is formed by compounding and bonding non-hygroscopic polyester and pure aluminum foil together; the thickness of the aluminum foil mylar tape winding belt is required to be 0.05mm; after water resistance (68 +/-1 ℃ and 168 hours), the peel strength between the aluminum tape and the plastic film is more than or equal to 9.0N/cm, the aluminum foil Mylar tape wrapping tape is uniformly overlapped and wrapped on the surface of the lining layer by a double-head wrapping machine, the aluminum surface faces outwards, and the wrapping and covering rate is not less than 5mm.
The aluminum foil mylar tape is wound without leakage and wrinkling.
4) The inner lining layer adopts a rubber extruding machine, and a mould core and a mould sleeve are arranged on a machine head; the aperture of the mold core is larger than the outer diameter of the cable core, and the aperture of the mold core = the diameter of the cable core plus 0.5mm; the aperture of the die sleeve = the diameter of the cable core +2 x the thickness of the thinnest part +0.5mm;
the body of the rubber extruding machine is cooled by a water cooling machine, the rubber extruding machine is fed to the discharging direction, and the continuous vulcanization temperature zone is as follows: the first area is 330-350 ℃, the second area is 260-280 ℃, the third area is 240-260 ℃, the fourth area is 180-200 ℃, the fifth area is 180-200 ℃, the sixth area is 160-180 ℃, the seventh area is 160-180 ℃ and the eighth area is 160-180 ℃; wherein: the first zone, the second zone, the third zone and the fourth zone are vulcanization shaping zones, and the fifth zone, the sixth zone, the seventh zone and the eighth zone are constant temperature vulcanization heat preservation sections.
Cooling the rubber extruding machine body by a water cooler at a constant temperature of 5-20 ℃;
the melting pressure is kept between 120 and 160bar when the lining layer is extruded, the thinnest part of the lining layer is 0.30mm, and the eccentricity is not more than 25 percent.
The main properties of the cable of the present example were tested as follows:
1) Endurance reliability, heat resistance: through the detection of a national third-party test, the product passes 150 ℃ x 3000h,175 ℃ x 240h aging, 192h ozone resistance test, 750h weather-resistant accelerated aging test, 200 ℃ x 6h overload aging and pressure resistance test, and all reach the design standard.
2) The soft performance is as follows: the flexible bending radius of the product reaches 4D (D is the outer diameter of the cable), the temperature of +/-90 ℃ is met, 15 times of circulation per minute are achieved, and the conductor and the shielding layer are normally conducted after 5000 times of circulation testing. The design structure can meet the requirements of convenient laying and wiring and is not limited by space.
3) EMC shielding effectiveness meets the design standard requirement of 30MHz-500MHz through the shielding structure and the shielding parameter setting, and the attenuation is actually measured to 73dB.
4) Flame retardant property: the material for the product passes the UL94-VO flame retardant test detection, and meets the use requirement of the wire harness. The finished cable passes the requirements of a UL1581 standard VW-1 flame-retardant test.
5) Electrical withstand voltage test: and the pressure resistance test of the product before and after the endurance test and the conventional test meets the design standard requirement.
6) Chemical reagent resistance: through reliability test evaluation, the test of chemical liquids such as cooling liquid, steering liquid, engine oil, battery acid and the like can be simultaneously met.
Claims (8)
1. A high temperature resistant anti-interference flexible cable is formed by stranding wire cores to form a cable core, and a protection layer is arranged outside the cable core, and is characterized in that the wire cores comprise a ground wire core and a plurality of power wire cores which are stranded to form the cable core, and a flexible temperature resistant twisted fiber is filled at the axial position of the cable core;
the protective layer comprises a composite shielding layer and an outer protective layer which are wrapped outside the cable core from inside to outside; the gaps among the wire cores in the composite shielding layer are filled with an inner lining layer made of flexible temperature-resistant materials;
the composite shielding layer comprises an inner aluminum foil metal shielding layer, a tinned copper wire woven mesh and an outer aluminum foil metal shielding layer from inside to outside;
the inner aluminum foil metal shielding layer and the outer aluminum foil metal shielding layer are formed by overlapping and wrapping aluminum foil mylar tapes;
the tinned copper wire weaving net is formed by weaving tinned copper wires, the diameter of each tinned copper wire is not more than 0.2mm, the weaving pitch is 28-32 mm, and the weaving density is 88-90%.
2. The flexible cable of claim 1, wherein the aluminum foil mylar tape of the inner and outer aluminum foil metal shielding layers have a thickness of 0.05mm.
3. The high temperature resistant anti-interference flexible cable of claim 1, wherein the aluminum surface of the aluminum foil mylar tape of the inner aluminum foil metal shielding layer faces away from the cable core, and the width of the lapping cover is not less than 5mm;
the aluminum surface of the aluminum foil mylar tape of the outer aluminum foil metal shielding layer faces the cable core, and the lapping and covering rate is not less than 25% of the bandwidth;
the performance requirement of the aluminum foil wheat pulling strip is that the requirement of RoHS2.0 determination in RoHS instruction 2015/863/EU is met.
4. The high temperature resistant anti-interference flexible cable according to claim 1, wherein the braiding angle of the tinned copper wire braided mesh ranges from 35 ° to 40 °.
5. The high temperature resistant anti-interference flexible cable according to claim 1, wherein the ground core and the power core are respectively composed of a conductor and an insulating layer wrapped outside the conductor;
the conductor is an annealed soft copper conductor composed of 6 types of monofilaments; the diameter range of the monofilament is 0.1-0.20 mm.
6. The high temperature resistant anti-interference flexible cable according to claim 5, wherein the conductors of the power wire core and the ground wire core are of a twice-multiple-stranded conductor structure: a plurality of monofilaments are twisted into a bundle, and the monofilaments of each bundle are combined and bundled to form a folded yarn; the ratio of the twisting pitch diameter of the outermost layer of the compound twisting is not more than 14 times, and the direction of the inner layer and the outer layer is in the left direction.
7. The high temperature resistant anti-interference flexible cable according to claim 1, wherein the flexible temperature resistant twisted fiber filling is a twisted composite filling rope.
8. The high temperature resistant anti-interference flexible cable according to claim 1, wherein the thickness of the insulating layer is 0.40mm to 1.20mm; the thickness of the inner liner is 0.3 mm-0.8 mm; the thickness of the sheath layer is 1.2 mm-1.8 mm.
Priority Applications (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202222257434.2U CN218631427U (en) | 2022-08-26 | 2022-08-26 | High temperature resistant anti-interference flexible cable |
Applications Claiming Priority (1)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| CN202222257434.2U CN218631427U (en) | 2022-08-26 | 2022-08-26 | High temperature resistant anti-interference flexible cable |
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| Publication Number | Publication Date |
|---|---|
| CN218631427U true CN218631427U (en) | 2023-03-14 |
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| Application Number | Title | Priority Date | Filing Date |
|---|---|---|---|
| CN202222257434.2U Active CN218631427U (en) | 2022-08-26 | 2022-08-26 | High temperature resistant anti-interference flexible cable |
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| CN (1) | CN218631427U (en) |
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- 2022-08-26 CN CN202222257434.2U patent/CN218631427U/en active Active
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